Method and arrangement for constructing and interconnecting prefabricated building modules

ABSTRACT

A modular building system allows for quickly and easily erecting prefabricated wall panels on a building foundation at a construction site. The system allows for manufacturing and installing, at a high level, complete budding components, using steps that are highly repeatable and scalable, resulting in construction that is quick and efficient, and easily performed at many types and locations of construction sites. A system in accordance with the invention comprises a wall panel, a floor panel and a roof panel. The wall panel comprises a horizontal member supported along a bottom horizontal edge, and a plurality of vertical studs integral to the horizontal member and extending vertically downward from the horizontal member. A floor panel comprises a rail disposed rigidly fixed to the foundation and defining an enclosure to receive the plurality of vertical studs of the wall panel to thereby vertically position the wall panel upon the foundation.

RELATED APPLICATION(S)

This application claims priority under 35 U.S.C. § 119(e) of theco-pending U.S. Provisional Patent Application Ser. No. 63/152,793,filed Feb. 23, 2021, and titled “Building Blocks in ConstructionTechnology,” which is hereby incorporated by reference in its entirety.

FIELD OF THE INVENTION

The embodiments discussed in the present disclosure are generallyrelated to construction technology. In particular, the embodimentsdiscussed are related to construction and interconnection ofprefabricated building modules for use in construction technology.

BACKGROUND OF THE INVENTION

Existing construction technologies involve one-off (e.g., customized)build-on site approaches in which construction material is brought tothe construction site. This has been the traditional methodology andapproach for many years but has certain inherent challenges. Suchchallenges include non-availability of skilled workforce (e.g., manuallabor), heavy and expensive on-site machinery, incorrect estimate ofcompletion time of construction projects, delays in delivery ofprojects, weather, quality, wastage of materials, noise and airpollution, and cost involved in disposal of debris. This approach isalso “one-off” and provides no repeatability or scalability leverage.Each building or project is done differently, and results vary widely.

Further, execution of construction projects needs an ensemble oftechnologies/domains such as, structural integration, civil engineering,mechanical joints, material science, etc. Although, there have beensignificant advancements in construction technologies, due to the abovefactors, the average cost of construction and the effective cost ofowning a house is still high for a majority of aspiring owners.

In order to address the aforesaid shortfalls of these build-on siteapproaches, usage of prefabricated building modules for construction isalso commonplace and has been in practice for some time. For example,building modules could be prefabricated at factories under factoryscaling, repeatability, and in-factory conditions, and then delivered toa building site for expeditious on-site assembly. Prefabricated buildingmodules are broadly classified into volumetric and non-volumetric types.A volumetric prefabricated building module is understood to personsskilled in the art as one which has a volume defined by a structuredenclosure or boundary. A non-volumetric type is one wherein panels andother prefabricated components are stacked or packed together forstorage and shipment with minimum space in-between. For someconstruction sites, for example, remote sites which are in primitivelocations or otherwise too difficult to access, or where resources aredifficult to acquire, or when weather conditions or environmentalrestrictions do not permit, construction using prefabricated modules areoften the only practical option.

The prefabricated components typically comprise a solid roof, floor, andwall panels that are joined together during on-site assembling. Intypical configurations, wall panels, roof panels, and floors areinterconnected, for example, by an upwardly opening U-shaped profilebracket attached to a flooring member.

However, there remains a need in the art for constructing a modularhousing system based on improved and robust prefabricated components towithstand load, climate changes, and daily wear and tear as may besubjected to any house or establishment. Alternatively, there lies aneed for an improved and better quality roof, wall, floor panels, etc.,as may be used for constructing the modular housing system.

Further, there lies a need for mechanical or electromechnical connectorsfor all the prefabricated components for simplifying and standardizing aconnection across all the panels, allowing adjustment and/or replacementof the panels upon or after installation, and yet nonetheless providinga robust, dependable, water-tight interconnection. Such interconnectionneeds to be as robust as a permanent connection of a non-modularbuilding system made of non-prefabricated components to not compromisequality.

SUMMARY OF THE INVENTION

Embodiments for constructing and interconnecting building blocks/modulesin construction technology are disclosed that address at least some ofthe above challenges and issues.

In a first aspect, the present subject matter is directed to a modularbuilding system, comprising a wall panel and a floor panel. The wallpanel comprises a plurality of sheets disposed adjacently, a horizontalmember supported along a bottom horizontal edge formed by adjacentdisposition each of said sheets, and a plurality of vertical studsintegral to the horizontal member and extending vertically downward fromthe horizontal member. The floor panel comprises a rail rigidly fixed tothe ground or other foundation and defining an enclosure to receive theplurality of vertical studs of the wall panel and thereby verticallysupport the wall panel upon the foundation.

In an alternative embodiment, the plurality of sheets of the wall panelcomprises a gypsum board, a plurality of metal studs to support thegypsum board, a plurality of metal column studs placed between the metalstuds, mineral wool disposed between the metal studs, a sheathing boardcomprising a first cement board, an insulation layer, and an externalcladding layer comprising a second cement board.

In an alternative embodiment, the modular building system furthercomprises a roof panel having a plurality of layers comprising one ormore of a waterproofing membrane, a sheathing board, a plywood layer, alight gauge steel (LGS) based structure exhibiting a slope with respectto a surface of the waterproofing membrane, and a gypsum board ceiling.The roof panel further comprises a plurality of metal column studsinterspersed in mineral wool above and below the LGS structure, whereinthe mineral wool is held between the sheathing board above and below theLGS structure. An external cladding layer and an insulation layer arefurther provided.

In an alternative embodiment, each of the wall panel and the roof panelfurther comprises one or more connectors for achieving a connection withone or more of the wall panels and an other roof panel. The connectorwithin the wall panel and the roof panel comprises at least one firstvertical stud supported along a first vertical face, and at least onesecond vertical stud supported along a second vertical face opposite thefirst vertical face.

BRIEF DESCRIPTION OF THE DRAWINGS

Further advantages of the invention will become apparent by reference tothe detailed description of preferred embodiments when considered inconjunction with the drawings. In the drawings, identical numbers referto the same or a similar element.

FIGS. 1(a) and (b) illustrate a wall panel and a floor panel duringdifferent stages of installation in construction technology inaccordance with an embodiment.

FIGS. 2(a) and (b) illustrate, respectively, the wall panel of FIG. 1 asmounted upon the floor panel and a cross-sectional view of the wallpanel in accordance with an embodiment.

FIG. 3 illustrates an exploded view of the wall panel of FIG. 2 detachedfrom the floor panel in accordance with an embodiment.

FIGS. 4 (a) and (b) illustrate an arrangement for lifting the wall panelin accordance with an embodiment.

FIG. 5 illustrates an elevation view depicting a wall panel to wallpanel connection in accordance with an embodiment.

FIG. 6 illustrates an elevation view depicting an integrated view of thewall panel to wall panel connection of FIG. 5 in accordance with anembodiment.

FIG. 7 illustrates an example roof panel in accordance with anembodiment.

FIG. 8 illustrates a sectional view of the roof panel of FIG. 7 inaccordance with an embodiment.

FIG. 9 illustrates an example step of connecting roof panels inaccordance with an embodiment.

FIGS. 10(a), (b) and (c) illustrate other example steps of connectingroof panels in accordance with an embodiment.

FIG. 11 illustrates yet another example step of connecting roof panelsin accordance with an embodiment.

FIG. 12 illustrates yet another example step of connecting roof panelsin accordance with an embodiment.

FIG. 13 illustrates method steps of installation of panels in accordancewith an embodiment.

DETAILED DESCRIPTION

The following detailed description is presented to enable any personskilled in the art to make and use the invention. For purposes ofexplanation, specific details are set forth to provide a thoroughunderstanding of the present invention. However, it will be apparent toone skilled in the art that these specific details are not required topractice the invention. Descriptions of specific applications areprovided only as representative examples. Various modifications to thepreferred embodiments will be readily apparent to one skilled in theart, and the general principles defined herein may be applied to otherembodiments and applications without departing from the scope of theinvention. The present invention is not intended to be limited to theembodiments shown, but is to be accorded the widest possible scopeconsistent with the principles and features disclosed herein.

With modernization in construction-related technologies, there has beena rapid shift from normal customized build on-site constructionmethodologies to construction using modules or blocks that can be builtoff-site. However, in such an approach, it may be of utmost concern thatthe modules are manufactured in such a manner that they are easy totransport, integrate, assemble, or mount on any construction site.Current manufacturing technologies fail to address this concern. Theembodiments of the present disclosure address this concern by providingimproved, multi-layered and robust prefabricated components.

Yet another important consideration may be that the boundary conditionsof each module are sealed from the outside as well as insidecontinuously. In other words, the modules need to be structurally,mechanically, and aesthetically well connected/integrated with eachother. Such seamless integration of modules on the construction siteremains an unresolved challenge. The embodiments of the presentdisclosure address this challenge at least by providing improved androbust interconnecting arrangements among the prefabricated components.

While wooden studs were traditionally used to withstand a load of walls(interior and exterior) and roofs, steel studs have been employed andpreferred over wooden studs in the construction business due to theirvarious advantages. For example, steel studs are fire-resistant, rigid,lightweight, stable, and dimensionally controllable, and exhibit moreresistance to earthquakes and tornadoes. In addition, when compared withwooden studs, steel studs remain unaffected by problems like rotting,cracking, shrinking, and termite-attack.

Construction technology in this disclosure proposes the use of fullyloaded 2D Light Gauge Steel (LGS) panels for roof and walls coupled withother building blocks. The current disclosure also provides variousembodiments of bathroom pods, modular kitchen, precast foundation(s),and floors, to construct high quality, highly sustainablehomes/buildings while addressing the above noted concerns andchallenges. The disclosed solution/architecture provides an improvedmulti-layered assembly of prefabricated components such as roof panels,floor panels, and wall panels to withstand load, climate changes, anddaily wear and tear as may be subjected to any house or establishment.Further, the disclosed solution/architecture provides mechanical orelectromechnical connectors (e.g. female-male pair based or otherwise“matched” connectors) for all the prefabricated components forsimplifying and standardizing a connection across all the panels, whichin turn allows adjustment and/or replacement of the panels uponinstallation, and last but not the least provides a robust, dependable,water-tight interconnection amongst the panels.

Certain terms and phrases have been used throughout the disclosure andwill have the following meanings in the context of the ongoingdisclosure.

“LGS” refers to Light Gauge Steel framing, which is a constructiontechnology that uses cold-formed steel as a construction material.

“MEP” refers to Mechanical, Electrical, and Plumbing technicaldisciplines for making any building site suitable for human occupancy.

“HVAC” refers to Heating, Ventilation, and Air Conditioning systems forproviding heating and cooling to any building site.

“R-value” refers to a measure of thermal resistance, where R stands forresistance to heat flow. An R-value is specified for every layer ofmaterial, and United States energy codes only refer to the R-values ofinsulation layers in the prescriptive R-value compliance path.

“IECC” refers to the International Energy Conservation Code. IECCprovides three paths for compliance for a building envelope. The firstpath specifies the required minimum level of insulation in the wall,i.e., R-value; the second path specifies U-factors for the buildingenvelope components; and the third path, in which an annual energy useanalysis is required, is based on the total building energy cost budgetfor heating, cooling, and service water heating.

“SFH” refers to single-family home, which typically has one unitintended to house a single family.

“Wall panel” refers to a prefabricated multi-layered wall fabricated atan offsite location and installed on-site, wherein “on-site” denotes aconstruction site and “offsite” denotes away from the construction site.

“Floor panel” refers to a prefabricated multi-layered floor fabricatedat an offsite location and installed on-site.

“Roof panel” refers to a prefabricated multi-layered truss based rooffabricated at an offsite location and installed on-site.

“Horizontal track” refers to a rail component to vertically supportcomponents upon a foundation, ground or other origin.

“Vertical studs” refers to metallic columns or protrusions extendingfrom a structure and capable of being fastened to another structure toconnect both structures.

“Swaged studs” refers to male metallic connectors for mechanicallinkage.

“Unlipped studs” refers to female metallic connectors for acting as areceptacle to the “Swaged studs”.

“Modular” refers to any mechanism involving arrangement of individualand independent blocks.

In accordance with the embodiments of the invention a modular buildingsystem comprises a wall panel, a floor panel, and a roof panel. The wallpanel comprises a horizontal member supported along a bottom horizontaledge of the wall panel and a plurality of vertical studs integral to thehorizontal member and extending vertically downward from the horizontalmember. A floor panel comprises a rail disposed rigidly fixed to theground and defining an enclosure to receive the plurality of verticalstuds of the wall panel to vertically position the wall panel upon theground.

In accordance with the embodiments of this disclosure, the rail is ahorizontal track riveted to the ground and accommodates the verticalstuds of the wall panel.

In accordance with the embodiments of this disclosure, the verticalstuds of the wall panel are screw-fastened to the horizontal track.

In accordance with the embodiments of this disclosure, the wall panelfurther comprises one or more connectors for achieving a connection withan other wall panel, said one or more connectors comprising at least oneof: a first vertical stud supported along a first vertical edge of thewall panel, and a second vertical stud supported along a second verticaledge opposite the first vertical edge of the other wall panel.

In accordance with the embodiments of this disclosure, the firstvertical stud and the second vertical stud comprise a pair of male andfemale connectors to connect the wall panel with the other wall panel,and wherein the first vertical stud of the wall panel connects with thesecond vertical stud of the another wall panel through a screw fastener.

In accordance with the embodiments of this disclosure, the wall panelfurther comprises a plurality of sheets disposed adjacently, wherein theplurality of sheets of the wall panel comprise one or more of: a gypsumboard, a mineral wool disposed between metal studs, a sheathing boardcomprising a first cement board, an insulation layer, and an externalcladding layer comprising a second cement board.

In accordance with the embodiments of this disclosure, a roof panel hasa plurality of layers comprising one or more of a water proofingmembrane, a sheathing board, a plywood layer, and a false ceiling.

In accordance with the embodiments of this disclosure, the roof panelfurther comprises a light gauge steel (LGS) based structure having anelevation angle relative to a surface of the water proofing membrane, aplurality of metal column studs interspersed in mineral wool above andbelow the LGS structure, an arrangement to connect with the wall panel,and a cantilever arrangement.

In accordance with the embodiments of this disclosure, the roof panelfurther comprises one or more connectors for achieving a connection withone or more of the wall panel and another roof panel, said connectorscomprising at least one first vertical stud supported along a firstvertical face, and at least one second vertical stud supported along asecond vertical face opposite the first vertical face.

In accordance with the embodiments of this disclosure, the at least onefirst vertical stud and the at least one second vertical stud comprise apair of male and female connectors to connect the roof panel with another roof panel, and wherein the at least one of the roof panelconnects with the at least one second vertical stud of the other roofpanel through a screw fastener.

FIG. 1 illustrates a wall panel and a floor panel in constructiontechnology in accordance with an embodiment. As such, FIG. 1 illustratesbuilding blocks comprising a wall panel 102 and a floor panel 104 inconstruction technology in accordance with an embodiment of the presentdisclosure. The building blocks include the wall panel 102, the floorpanel 104, and a roof panel (shown below in FIG. 7 ). In thisembodiment, although three building blocks are illustrated, it will beapparent to a person with ordinary skill in the art that a building mayalso be constructed using any number of building blocks on a precastmodular foundation. In an embodiment, each of the aforesaid buildingblocks may include sub-modules or sub-blocks that can be independentlymanufactured and assembled in a factory setting. In an embodiment, thebuilding blocks may be assembled as part of a modular home, where themodular blocks are built entirely in a factory setting and subsequentlyassembled or mounted on the construction site. In another embodiment,one or more building blocks may be built in the factory while otherbuilding blocks of the building may be built on-site. In an embodiment,any combination of building blocks may be built on-site and off-site toconstruct a home/building. For each building block illustrated in FIG. 1, placement details will be explained in detail in forthcoming figures.

The floor panel 104 comprises a rail or a horizontal track, i.e. aswaged/unlipped stud that provides an enclosure and thereby acts as areceptacle for the studs of the wall panel 102. The horizontal track isrigidly fixed (e.g., riveted) to the ground and defines an enclosure toreceive a plurality of vertical studs (shown in FIG. 2 and FIG. 3 below)of the wall panel 102 and thereby vertically support the wall panel 102upon the ground. As shown in FIG. 1 a , the wall panel 102 may be liftedand dropped upon the horizontal track of the floor panel 104. Thehorizontal track of the floor panel 104 acts as the receptacle for theplurality of vertical studs which are provided at the bottom of the wallpanel 102. As further shown in FIG. 1 b , the wall panel 102 is placedupon the floor panel 104. In such a scenario, the vertical studs of thewall panel 102, once received within the floor panel 104, are fastenedto the walls of the horizontal track of the floor panel 104 on bothinterior and exterior sides, such as by screw fastening. As may beunderstood, the screw fastening affords replaceability, versatility,time efficiency of fastening and robustness. Here the fastening may bealso construed to cover other analogous mechanisms, such as welding orself-tapping screw fastening, which requires no pilot holes orprelocation. In an example, the receiving of the vertical studs withinfloor panel 104 may comprise coupling with a male-female mechanicalconnection such that vertical studs may comprise a male connector andthe floor panel 104 may comprise a female connector.

FIGS. 2(a) and (b) illustrate, respectively, the wall panel 102 asmounted upon the floor panel 104 and a cross-sectional view of the wallpanel 102 in accordance with an embodiment. FIG. 2 will be explained inconjunction with the description of FIG. 1 . In particular, FIG. 2illustrates the wall panel 102 as mounted upon the floor panel 104 and across-sectional view of the wall panel 102 in the mounted state.

FIG. 2 a shows an exploded view depicting the wall panel 102 above, andthereby detached from, the floor panel 104. One face of the wall panel102 may be provided with a pair of adjacently placed terminationflashings 202-1 and 202-2 at the bottom of the wall panel 102. As may beunderstood, termination flashing may be a multi-purpose, preformed,professional way to attach a wide variety of construction waterproofing,drainage boards, and panel systems. The termination flashing 202-1 maybe powder-coated aluminum termination flashing which, as one example,may be Tamlyn or equivalent without departing from the scope of theongoing description. The termination flashing 202-2 may be powder-coatedaluminum L flashing or equivalent without departing from the scope ofthe ongoing description.

As one example, the horizontal track of the floor panel 104 is rivetedor otherwise fastened to a foundation or the ground 204, for example,through a pneumatic pin fastener 206. As may be understood, thepneumatic pin fastener 206 is a rivet type connector that is driven bytools powered by air delivered from an air compressor. The foundation204 may be formed of reinforced cement concrete (RCC) or any equivalentwithout departing from the scope of the ongoing description. In anotherexample, the horizontal track 104 may also be installed within thefoundation 204 by using, for example, a cement concrete mixture insteadof the pneumatic pin fastener 206.

In another example, instead of RCC, the foundation or ground 204 mayitself be a prefabricated panel comprising an R-15 Rigid PolyurethaneFoam Insulation layer that may be placed contiguously followed,sequentially, by a Moisture Barrier layer, a Granular fill layer, and aSubgrade. In an embodiment, the thickness of the R-15 Rigid PolyurethaneFoam Insulation layer may be 3 inches. In an embodiment, alternativelybatt insulation may be used instead of R-15 Rigid Polyurethane FoamInsulation layer. The quick join-and-attach features of the wall panel102 facilitate rapid placement, assembly, and dimensional predictabilityamongst other things.

FIG. 2 b shows the wall panel 102 and the floor panel 104 connected toeach other and a subsequent floor finishing and skirting, as may beperformed post connection, to achieve a seamless connection. Morespecifically, following the wall panel 102 placement over the floorpanel 104, finished flooring and base trim may be performed. A result ofsuch finishing has been denoted by reference number 208. Additionally, azip system sheathing 210 may be provided as insulation post fastening ofthe wall panel 102 with the floor panel 104. In an example, theinsulation as provided by zip system sheathing 210 may be thermal,electrical or a combination of both. It will be appreciated that, as inother figures described herein, the layers shown in FIG. 2(b) may becoupled others, such as through intermediate layers (not shown).

Zip-type sheathing provides several advantages. For example, the rigidfoam isolation board is attached, providing the building-code-requiredthermal break between the sheathing and the steel stud. Additionally,the zip outside the sheathing provides for direct mechanical/structuralattachment of any siding (e.g., cement board, rain screen, masonry,stucco, etc.).

FIG. 3 illustrates an exploded view to depict the wall panel detachedfrom the floor panel in accordance with an embodiment. FIG. 3 will beexplained in conjunction with the descriptions of FIG. 1 and FIG. 2 .

FIG. 3 illustrates an exploded view of the structure of FIG. 2 ,depicting the wall panel 102 above, and thereby detached from, the floorpanel 104. Specifically, FIG. 3 illustrates an enlarged cross-sectionalview of the wall panel 102 to depict a structural composition of thewall panel 102 in accordance with an embodiment. The wall panel 102, forexample, may be a standard 4-feet grid-sized LGS wall panel, which isfully assembled in-factory using LGS for studs, structural frameworkwith insulation, windows (exterior), doors (interior and exterior), andsheathing. As one example, the wall panel 102 may be 8 feet wide and 11to 14 feet high. However, the dimensions of wall panel 102 are forillustration purposes only and may change in accordance with therequirements and/or design specifications, amongst any other factorswithin the scope of the present disclosure. In an embodiment, theinterior of the wall panel 102 may optionally include unplasticisedpolyvinyl chloride (UPVC) windows and the surrounding/remaining portionof the wall panel 102 may be layered by interior finishes.

There are notable advantages of the depicted wall panel 102 such as itsquick-join features which allow for the rapid assembly of extendablewalls, and enable dimensional predictability as further depicted in FIG.5 and FIG. 6 . Further, lifting features and packing of the wall panel102 allow for fast and accurate logistics and assembly on-site asfurther depicted in FIG. 4 . Overall, a modular design of the wall panel102 as depicted in FIG. 3 allows for flexible configuration,manufacturing, and assembly processes. Additionally, the combinedjoining techniques allow for a very high level of finish (in some cases,as high as 85%) of components directly out of factory.

As depicted in the cross-sectional view of the wall panel in FIG. 3 ,the wall panel 102 comprises a plurality of sheets or layers 301-306disposed adjacently. On the interior side of the wall panel 102, agypsum board 301 is placed. In an embodiment, the gypsum board 301 mayhave a thickness of about 1-1.5 inches. A gypsum board may be understoodas a drywall used as a building material for wall, ceiling, andpartition systems in building structures.

The gypsum board 301 of the wall panel 102 may be supported by coldformed steel (CFS) based frames. Metal studs as a part of frame of thewall panel 102 may extend from the CFS frames. In one embodiment, themetal studs are 3.5-inch wide studs. However, such dimensions of metalstuds are for illustration purposes only and may vary based on internaland external factors or other specifications. Further, mineral wool orR-13 Batt insulation 302 may be placed between the metal studs, forexample, in the form of a close cell spray configuration for thermal andelectrical shock prevention due to the presence of metal studs. As maybe understood, in some embodiments the metal studs may be needed for arigid frame of the wall panel 102 but remain prone to electrical shockand thermal heating. The R-13 Batt insulation provides insulation forthe metal studs. In one embodiment, the zip sheathing has 1 inch foamboard attached directly to the steel studs (on the outside portion ofthe wall and/or roof trusses) to provide an electrical and thermalbreak. Typically, the insulation between the studs on the inside surfaceof the walls, trusses, or both is to meet any required local building Rperformance/standards. In an embodiment, the mineral wool has athickness of about 3.5 inches. However, the thickness of the mineralwool 302 may vary based on internal and external factors.

After the mineral wool 302 (e.g., traversing from the innermost to theoutermost layer), a rigid insulation layer 303 is placed, preferably toprovide a thermal break between the steel studs and outside finishes. Inan embodiment, the rigid insulation layer 303 may have a thickness ofabout 1 inch and may vary based on internal and external factors. Inanother embodiment, the rigid insulation layer 303 may comprise a Zipsystem R-6 rigid foam insulation board.

Subsequent to the layer of rigid insulation 303, a sheathing board 304is placed to provide both structural integrity and an outside surface tomount finish, roof materials, or both. In an embodiment, the sheathingboard 304 is “Zip System 7/16 inches plywood (OSB) sheathing.” Inanother embodiment, the sheathing board 304 may be an Oriented strandboard (OSB), MgO, cement board, etc. In another embodiment, thesheathing board 304 may have a thickness of about 0.5 inches. However,the dimensions of the sheathing board 304 are for illustration purposesonly and may vary based on various factors.

Next to the sheathing board 304, an external cladding layer 305 isplaced to provide the functionality of an external cement board asunderstood to a person skilled in art of building materials. In anembodiment, the external cladding layer 305 may be a cement board, about5/16 inches thick. However, a person skilled in the art may select otheravailable materials for external cladding layer 305 and accordinglyselect thickness based on design and purpose. The external claddinglayer 305 provides an outside wall finish and, as some examples, caninclude brick, stucco, rainscreen, metal, porcelain tile, etc., oranother material, similar to the zip outside layer, to provide an easymechanical connection of outside finishes. The external cladding layer305 may be joined with the sheathing board 304 using connector orjoining means such as metal clamps 306 for cladding. The metal clamps306 maybe “1 inches×2 inches” cement Board vertical members at 12 inchesoff center or 12 inches O.C. The number of metal clamps 306 to be usedmay depend on the number of wall panels. In an embodiment, the metalclamps 306 may be distributed evenly or unevenly between the cladding305 and the sheathing board 304 to maintain continuity of the wall panel102.

It will be appreciated that the sequence of layers is exemplary. Inother embodiments, the layers may be interposed in different sequences,some layers may be omitted, and others added.

Further, the wall panel 102 comprises a horizontal member 308 supportedalong a bottom horizontal edge formed by adjacent disposition of each ofsaid sheets 301-306. The horizontal member 308 may be a metal stud orCFS frame. Further, a plurality of vertical studs 310 are integratedwith the horizontal member 308 and extend vertically downward from thehorizontal member 308.

Further, as explained above, the floor panel 104 may comprise thehorizontal track which is an unlipped/insulated track installed orfastened to the foundation 204. As explained above, the horizontal trackof the floor panel 104 receives the metal studs such as the verticalstuds 310 to enable placement of the wall panel 102 upon the floor panel104 thereby vertically supporting the wall panel 102 upon the ground.Thereafter, the vertical studs 310 are screw-fastened with the floorpanel 104. As may be understood, screw fastening affords replaceability,versatility, time efficiency of fastening, and robustness.

FIGS. 4 (a) and (b) illustrate an arrangement for lifting the wall panel102 in accordance with an embodiment. FIGS. 4 (a) and (b) will beexplained in conjunction with the descriptions of FIGS. 1-3 .

FIG. 4(a) illustrates an arrangement for lifting the wall panel 102,including lifting hooks or hangers 402 provided at a top track 404 ofthe wall panel 102. Further, a number of service holes 406 are providedat the top track 404 within a pair of extended CFS frames 408 forreceiving the lifting hooks 402. Upon installation of the wall panel 102upon the floor panel 104, the extended CFS frames 408 may be removedfrom the wall panel 102. In an example, vertical studs may also beprovided at the top track 404 formed within the wall panel 102. Anexample roof panel as later depicted in FIG. 7 may be provided with ahorizontal track like the floor panel 104 to receive the vertical studsmounted at the top track 404 and thereby vertically connect the roofpanel with the wall panel 102.

FIG. 4(b) illustrates an example mechanism for holding and transferringthe wall panel 102 using the arrangement for lifting the wall panel 102as depicted in FIG. 4(a). In an example, the wall panel 102 may behoisted, lifted, positioned through either a mechanical arrangement suchas a pulley mechanism or electromechanically through a computercontrolled crane 410 or an equivalent lifting mechanism, and a camera orother sensing means for aligning the walls and roof panels. Such liftingmay be automated or semi-automated performed through a human operatorand/or artificial intelligence.

FIG. 5 illustrates an elevation view depicting a wall panel to wallpanel connection in accordance with an embodiment. FIG. 5 will beexplained in conjunction with the descriptions of FIGS. 1-4 .

FIG. 5 illustrates an elevation view depicting a wall panel to wallpanel mechanical connection between any two wall panels 102A and 102B(collectively, 102) through cooperation between the vertical studs,i.e., an unlipped stud 502 of a first wall panel (102A) and a swagedstud 504 of a second wall panel (102B). The unlipped stud 502 acts as areceptacle and thereby receives the swaged stud 504 to connect the wallpanels 102A and 102B adjacently. Both the unlipped stud 502 and theswaged stud 504 may be provided vertically along respective verticaledges (surfaces) of the wall panels 102A and 102B to thereby verticallyconnect the wall panels 102. Further, the unlipped stud 502 and swagedstud 504 comprise a pair of male and female connectors to connect wallpanel 102A with the wall panel 102B.

With respect to the wall panel 102A, the unlipped stud 502 may besupported along a first vertical edge as shown in FIG. 5 . Accordingly,although not shown in the FIG. 5 , the swaged stud 504 may also besupported within the same wall panel 102A along a second vertical edgewhich is opposite or behind the first vertical edge. Further, forachieving the connection, the wall panel 102A may be pushed against astationary wall panel 102B or vice-versa or both the panels 102A and102B may be pushed against each other to enable insertion or securing ofthe swaged stud 504 within the unlipped stud 502. In an example, theforce required for such a pushing operation is provided through either amechanical arrangement such as a pulley mechanism or electromechanicallythrough a computer controlled robotic arm (as later shown in FIG. 10 b). Such pushing operation may be automated or semi-automated, performedthrough a human operator and/or artificial intelligence.

FIG. 6 illustrates an elevation view depicting an integrated view of thewall panel to wall panel connection in accordance with an embodiment.

FIG. 6 illustrates an elevation view depicting an integrated view of thewall panel to wall panel connection. The connection may be a mechanicalconnection between the two wall panels 102 through a screw-fastenersecurely attaching the unlipped stud 502 of the wall panel 102A with theswaged stud 504 of the wall panel 102B. The unlipped stud 502 and theswaged stud 504 may be metallic or any other alloy based studs. In otherwords, the unlipped stud 502 of the wall panel 102A receives the swagedstud 504 of the wall panel 102B and both are secured together through ascrew fastener 602. As depicted in FIG. 6 , the wall panels 102A and102B are joined to form a continuous wall. In an example, at thejunction between the two wall panels 102, there may be an expansion gapcovered or otherwise hidden by extra cladding material. The dimensionsof wall panels 102 depicted in FIGS. 1 to 6 are for illustrationpurposes only and may vary from one construction site to another.

FIG. 7 illustrates an example roof panel in accordance with anembodiment. FIG. 7 will be explained in conjunction with the descriptionof FIGS. 1-6 .

FIG. 7 illustrates an elevation view of a roof panel 700 in accordancewith an embodiment. The roof panel 700 is built using LGS modularconstruction. Each exemplary roof panel 700 can be built as a modulein-factory and completed with joists, plywood, insulation, and a falseceiling. As previously shown in FIG. 4 , the roof panel 700 may bemounted on the top track 404 of wall panel 102 for quick attachment andassembly.

The roof panel 700 includes a waterproofing membrane 702 that may forexample be a Thermoplastic Polyolefin (TPO) single ply roofing laid overan ISO rigid insulation which is followed by a rigid insulation layer.In an embodiment, the thickness of the rigid insulation layer may beabout 2 inches. However, the dimensions of the rigid insulation layermay vary based on internal and external factors. The rigid insulationlayer is followed by a plywood layer 704. The plywood layer 704 maybe a⅝″ OSB plywood decking. In some embodiments, the plywood layer 704provides the same function as the outside wall finish described above.

The plywood layer 704 is supported by a light gauge steel (LGS) roofjoist 706 with about ½ degree slope or alternatively exhibiting anelevation angle of 45°. It may be noted that the degree of slope mayvary based on the specifics and requirements of the construction site.In an embodiment, the LGS roof joist 706 may be followed by a falseceiling 712 that in turn may comprise a gypsum board 712. In anembodiment, a batt type insulation 708 (e. g. R-38 Batt Insulation) maybe used in the cavity of the roof panel 700 for R38 roof performance.

Metal column studs 710 above and below the LGS roof joist 706 may becovered by the batt type insulation's 708 mineral wool. In anembodiment, the metal column studs 710 may be about 3.5 inches by 3.5inches and correspond to a CFS Truss 3.5 inches box design at 24 O.C. Inan embodiment, the thickness of mineral wool covering the metal columnstuds 710 may be 3.5 inches. In an embodiment, the thickness of theplywood layer 704 on either side of the mineral wool is 0.5 inch.

In an example, although not shown in FIG. 7 , the plywood layer 704 maybe followed by rigid insulation and external cladding layers. Theexternal cladding layer and the rigid insulation layer are attached toeach other using metal clamps for cladding. In an embodiment, theexternal cladding layer may be 0.5 inch thick cement board. Aluminum(AL) coping may be used to cover the structural components and/or layersup to the external cladding layer for weather sealing.

Further, the roof panel 700 comprises a false ceiling, such as a gypsumboard ceiling 712, at the bottom, and an access panel 714 (for exampleof about 12 inches) adjacent to the gypsum board ceiling 712 tofacilitate fastening of trusses of the roof panel 700 with the wallpanel 102. As may be understood, a truss is a structure that consists ofmembers organised into connected triangles so that the overall assemblybehaves as a single object. Upon such fastening, the access panel 714may be finished with a cement board such as a gypsum board 720 toachieve a seamless connection. In addition, the roof panel 700 comprisesat the edge a termination flashing 716 for waterproofing/sealing. Acantilever arrangement may be provided in the form of an overhang 718that may be about 1 ft 4 inches long to render a balanced mounting ofthe roof panel 700 across the wall panel 102.

In accordance with an embodiment, the complete assembly fromwaterproofing membrane 702 at the top down to the gypsum board ceiling712 at the bottom constitutes the roof panel 700. Various units ormodules of the roof panel 700 as depicted may be joined and replicatedto form a complete roof at any construction site.

FIG. 8 illustrates a sectional view of the example roof panel inaccordance with an embodiment. FIG. 8 will be explained in conjunctionwith description of FIGS. 1-7 .

FIG. 8 illustrates a sectional view of the roof panel 700 to depictelectrical-equipment (s) provided as electrical fixtures and electricalcomponents within the roof panel 700. The electrical equipment asincluded within the roof panel 700 includes a raceaway 802 for housingand routing electrical wires across the roof panel 700. The electricalwires as routed are connected to an electrical box 804, which in anexample may be an electrical junction box (4×4) with or without a cover.A metal armored electrical cable 806, which for example corresponds to aWall Panel Whip, emerges from the electrical box 804 and is thereafterpacked/concealed within the mineral wool of the roof panel 700. Themetal armored electrical cable 806 upon emerging outside the roof panel700 is routed to an electrical load 808 or in another example a powersource such as an electrical socket. In an example, as later shown infigures, the various roof panels 700 upon having been mechanicallyconnected with each other may also be electrically connected eitherserially or in parallel as a daisy chain.

It will be apparent to a person with ordinary skill in the art thatdimensions and numbers utilized in the view of the roof panel 700 arefor illustration purposes only, and such types of roof panels, number ofunits, and dimensions may vary based on constructionsite/purpose/budget/requirements, etc.

FIG. 9 illustrates an example step of connecting roof panels inaccordance with an embodiment. FIG. 9 will be explained in conjunctionwith the descriptions of FIGS. 1-8 .

FIG. 9 illustrates an example step of mechanically connecting roofpanels 700A and 700B (collectively, 700) with each other in accordancewith an embodiment. Specifically, FIG. 9 represents an initial step ofconnecting the roof panels 700A and 700B such that panel 700B may belowered to be aligned to reach the same elevation as that of panel 700A.In an example, the panel 700B may be hoisted, lifted, positioned througheither a mechanical arrangement such as a pulley mechanism orelectromechanically through a computer controlled crane 906 or anequivalent hosting-lowering system. In an automated system, the crane906 and computer are coupled to a camera or other sensor for sensing thelocation of the walls, roof panels, and track relative to each other.Such lifting/lowering may be automated or semi-automated, performedthrough a human operator and/or artificial intelligence. Further, thepanel 700A and panel 700B are provided with an unlipped stud 902 and aswaged stud 904 on respective vertical faces as proposed to contact eachother to enable the mechanical connection between panel 700A and panel700 B.

With respect to the roof panel 700A, the unlipped stud 902 may besupported along a first vertical edge of roof panel 700A. Accordingly,although not shown in FIG. 9 , the swaged stud 904 may be supportedwithin roof panel 700A along a second vertical edge which is oppositethe first vertical edge.

FIGS. 10(a), 10(b) and 10(c) (collectively, FIG. 10 ) illustrate otherexample steps of mechanically connecting roof panels 700A and 700B inaccordance with an embodiment. FIG. 10 will be explained in conjunctionwith the description of FIGS. 1-9 .

FIG. 10 illustrates example steps of mechanically connecting roof panels700A and 700B (collectively, 700) with each other in accordance with anembodiment. As may be observed from FIG. 10 a , the panel 700B islowered and slid into proximity of panel 700A to enable the mechanicalcontact between the unlipped stud 902 and the swaged stud 904. As may beobserved from FIG. 10 b , as a part of such lowering-sliding operation,the roof panel 700B may be pushed against a stationary roof panel 700Aor both the panels 700A and 700B may be pushed against each other toenable insertion/securing of the swaged stud 904 within the unlippedstud 902. In an example, the force required for suchlowering-and-sliding operation is provided through either a mechanicalarrangement such as a pulley mechanism or electromechanically throughone or more computer controlled robotic arms 1002A and 1002B(collectively, 1002). Such a pushing operation may be automated orsemi-automated, performed through a human operator and/or artificialintelligence. Further, as may be observed from FIG. 10 c , the unlippedstud 902 acts as a receptacle to receive the swaged stud 904 and therebydefine a male-female connector pair between panel 700A and panel 700B.

FIG. 11 illustrates yet another example step of connecting the roofpanels 700A and 700B in accordance with an embodiment. FIG. 11 will beexplained in conjunction with the descriptions of FIGS. 1-10 .

FIG. 11 illustrates yet another example step of mechanically connectingroof panels 700A and 700B with each other in accordance with anembodiment. More specifically, FIG. 11 depicts screw fastening theunlipped stud 902 and the swaged stud 904 upon reaching the contactingposition or connection as depicted in FIG. 10 b . For effecting thisscrew fastening mechanism, a TPO membrane 1102 corresponding to the TPOmembrane 702 as depicted in FIG. 7 may be lifted for either one or boththe panels 700A and 700B to thereby expose the contacting unlipped stud902 and the swaged stud 904 and provide an ease of incorporating a screwfastener therebetween. Thereafter, the contacting studs 902, 904 asexposed are screw-fastened with each other. For example, for screwfastening, a through-bore may be created across the studs 902, 904through an example drill machine-based mechanism to achieve a drilledportal hole. Thereafter, a threaded bolt may be inserted through thethrough-bore and a threaded nut may be used to lock the threaded boltand achieve the screw-fastening.

FIG. 12 illustrates yet another example step of connecting roof panelsin accordance with an embodiment. FIG. 12 will be explained inconjunction with the descriptions of FIGS. 1-11 .

FIG. 12 illustrates yet another example step of mechanically connectingroof panels 700A and 700B with each other in accordance with anembodiment. Specifically, post achievement of screw fastening betweenthe unlipped stud 902 and the swaged stud 904 depicted in FIG. 11 , thelifted TPO membranes 702 of either one or both panels 700A and 700B inFIG. 11 are now welded together to achieve seamless connectivity at thetop of both panels A and B.

FIG. 13 illustrates method steps of installation of panels in accordancewith an embodiment. FIG. 13 will be explained in conjunction with thedescriptions of FIGS. 1-12 .

FIG. 13 illustrates the steps of a method 1300 of installing one or moreprefabricated wall panels 102 on a building foundation, i.e., the floorpanel 104, followed by installation of the roof panels 700 upon the wallpanels 102. Although specific operations are disclosed in FIG. 13 , suchoperations are examples. In different embodiments, to name only a fewexamples, the method 1300 may include other operations, the sequence ofthe operations can be modified, some steps may be omitted, or anycombination of these variations may be incorporated. The steps of method1300 may be automated or semi-automated. In various embodiments, one ormore of the operations of the method 1300 can be controlled or managedby software, by firmware, by hardware, or by any combination thereof,but is not limited to such.

Method 1300 can include processes of various embodiments of the presentdisclosure which can be controlled or managed by a processor(s) andelectrical components under the control of a computer or computingdevice comprising computer-readable and executable instructions or code.The readable and executable instructions (or code) may reside, forexample, in data storage such as volatile memory, non-volatile memory,and/or mass data storage, as only some examples. As explained later,automation of method 1300 through computer employs various peripheralssuch as sensors, robotic arms etc. to operate upon panels 102, 104 and700 during installation.

To generalize the explanation that follows, it is presumed that thefirst prefabricated wall 102A has already been erected, and the secondprefabricated wall 102B is to be erected so that the two are adjacent toeach other. However, such generalized description is merely for sake ofsimplicity of explanation and present subject matter may also beconstrued to cover simultaneous installation of all panels 102, 104 and700 without any prior implementation.

It will be appreciated that the steps to erect wall panels 102A aresimilar to those for wall panel 102B, except that no adjacent wall hasyet been installed. In this example, in an initial step, the “next” wallpanel is the first wall panel 102A. In this initial step, no “adjacent”wall panel has yet been installed. In the second iteration, describedbelow, the “next” wall panel is the second wall panel 102B, and the“adjacent” wall panel is the wall panel 102A.

At step 1302, a second (“next”) wall panel 102B is obtained. The secondwall panel 102B may be hooked on a top track 410 along a top horizontaledge of the second wall panel 102B in accordance with the description ofFIG. 4 .

At step 1304, the second wall panel 102B is positioned to align with therail 104 and any other adjacent wall panel (here, the first wall panel102A). More specifically, in step 1302, the hooked wall panel 102B islowered onto the rail 104 and thereafter released from the hook. Forsuch purposes, the second prefabricated wall panel 102B having a bottomhorizontal surface with a second bottom connector 310B (here, the label“B” denoting a component of the second wall panel 102B) is lowered ontothe rail 104 coupled to a foundation 204 of a building, the rail 104having a top horizontal surface with a top connector. The second bottomconnector 310B comprises studs and the top connector of the rail 104comprises recesses or enclosures configured to receive the studs 310B.The second wall panel 102B further comprises a second side surface witha wall connector 502B configured to couple the second wall panel 102B tothe first wall panel 102A, the first wall panel 102A comprising a firstside surface with a first wall connector matched to the second wallconnector. The first wall connector comprises an unlipped stud 502A, andthe second wall connector comprises a swaged stud 504B. The second wallpanel 102B may also be lowered towards the rail 104, the second wallpanel having a second bottom horizontal surface comprising a secondbottom connector 310B, until at least a portion of the second bottomconnector 310B is inserted into the rail 104. The second wall panel 102Bmay be moved or pushed so that the second side connector or the swagedstud 504B aligns with the first side connector or the unlipped stud502A.

At step 1306, the second wall panel 102B is fixedly coupled to the rail104 and the adjacent wall panel, the first wall panel 102A. The secondbottom connector 310B is coupled to the top connector of the rail 104 tosecure the second prefabricated wall panel 102B to the rail 104, therebyvertically affixing the second wall panel 102B to the foundation 204.More specifically, the second bottom connector 310B is screw-fastened tothe rail 104. Further, the first side connector 502A and the second sideconnector 504B are also fastened together through screw fastening toachieve coupling there-between.

At step 1308, a roof panel 700B is retrieved.

At step 1310, the roof panel 700B is positioned to align with the wallpanels 102A, 102B and any adjacent roof panel, here, first roof panel700A. More specifically, the roof panel 700B is secured over tophorizontal edges 410B of the second wall panel 102B and the first wallpanel 102A through a truss. Further, the roof panel 700B maybe sidewisesecured to the other (e.g., adjacent) roof panel 700A in accordance withthe description of FIG. 9 and FIG. 10 .

At step 1312, the roof panel 700B is fixedly coupled with the wallpanels 102A, 102B and the adjacent roof panel 700A through screwfastening or welding, to name only a few examples, as explained in thedescriptions of FIG. 9 to FIG. 12 .

At step 1314, it is checked if there are any further panels pending forinstallation from amongst the panels 102 and 700. If yes, then a controlis transferred back to the step 1302 to undergo further iterations ofthe method 1300. Otherwise, the method 1300 terminates.

In one aspect, a system for performing the steps 1300 is automated. Asone example, referring to FIG. 9 , the system comprises (1) a cameraarrangement, optical sensor, or other sensor arrangement (e.g., lightsource 950 and sensor 955) for sensing the relative locations of thecomponents, including the wall panels 102A and 102B, rail 104, and roofpanels 700A and 700B, (2) a crane 906 for hoisting, lowering, andadjusting the components relative to each other, (3) an arm (e.g., cranearm 912 or robotic arms 1002A and 1002B, FIG. 10(b)) for securing thecomponents to each other, and (3) a computer operatively coupled to thecrane 906, the crane arm 912, and the robotic arms 1002A and 1002B, thecomputer receiving the relative locations and, using the relativelocations, the crane, and the arm (crane arm, robotic arm, or both)performing the steps 1300. Preferably, the computer comprises a memorystoring computer-executable instructions that when executed perform thesteps 1300. In different embodiments, a single robot arm or a pair ofrobot arms can be used to hoist/lower components, align them, and securethem in place. In some embodiments, any combination of cranes, cranearms, and robot arms may be referred to as a “robot assembly.” In oneembodiment, the sensor arrangement comprises a light source 950positioned at the rightmost portion of FIG. 9 and a sensor 955positioned at the leftmost portion, aligned such as to determine thatthe wall panels 102A and 102B, roof panels 700A and 700B are aligned. Inone embodiment, the light pattern/intensity from the light source 950impinging on the sensor 955 indicates a degree of alignment between thefront surfaces of the panels 120A and 120B.

While FIG. 9 shows a light source 950 and sensor 955 positioned on theright and left portions of FIG. 9 (e.g., on opposite vertical sides ofthe wall panels so that light is directed at the vertical faces of thewall panels), it will be appreciated that light source-sensor pairs canalso be positioned at other locations to determine whether wall panelsand roof panels are aligned with each other and the rail. Alternatively,or in addition, a camera capable of determining the depth of objectsfrom the camera and from each other can be positioned to face the frontfaces, back faces, or both, of the panels to also align components.After reading this disclosure, those skilled in the art will recognizeother structures for determining the position and alignment of the wallpanels, roof panels, and rails.

In an example, the wall panel 102, the floor panel 104 and the roofpanel 700 may be connected together as explained in the precedingfigures to achieve a rapid construct cross-section in accordance with anembodiment. The rapid construct cross-section may be an LGS modularconstruction. A plurality of blocks, such as the rapid constructcross-section may be combined to allow rapid on-site assembly andcompletion of the house. In an embodiment, the rapid constructcross-section may be used for SFH.

The rapid construct cross-section includes a bottom portion similar tothe floor panel 104 discussed previously in FIGS. 1 to 3 . The bottomportion of the rapid construct cross-section is attached to thefoundation 204. A middle portion of the rapid construct cross section issimilar to the wall panel 102 discussed previously in FIG. 1 to FIG. 6 .The top portion of the rapid construct cross section is similar to theroof panel 700 and roof panel details illustrated and discussedpreviously in FIG. 7 to FIG. 12 . Therefore, a person with ordinaryskill in the art will ascertain that, in accordance with one embodiment,the rapid construct cross section comprises a combination of buildingblocks such as the floor panel 104, the wall panel 102, and the roofpanel 700.

The rapid construct blocks as may be obtained due to their constructiontechnology, are high quality, forming repeatable and scalable SFHproducts. They form an IECC energy compliant high-performance envelope.

With reference to the building blocks disclosed in FIGS. 1-13 , it is tobe noted that various joining methodologies and/or technologies may beutilized to join sub-modules/sub-units of individual building blocks orto join one building block with another. For example, joiningtechnologies may be used to build modular building blocks that whenassembled make a building envelope/enclosure structurally andenvironmentally seamless. In another example, interconnectionmethodologies may be used between foundation and wall; wall and wall;wall and roof truss; and roof truss and roof truss. In yet anotherexample, interconnection methodologies may be used that speed upassembly processes and reduce the need for skilled labor. In yet anotherexample, interconnection technologies may be used that allow a highdegree of module completion in the factory. In yet another example,digitization of modular building blocks may enable repeatability withhigher quality levels than traditional methodologies.

The terms “comprising,” “including,” and “having,” as used in thespecification herein, shall be considered as indicating an open groupthat may include other elements not specified. The terms “a,” “an,” andthe singular forms of words shall be taken to include the plural form ofthe same words, such that the terms mean that one or more of somethingis provided. The term “one” or “single” may be used to indicate that oneand only one of something is intended. Similarly, other specific integervalues, such as “two,” may be used when a specific number of things isintended. The terms “preferably,” “preferred,” “prefer,” “optionally,”“may,” and similar terms are used to indicate that an item, condition,or step being referred to is an optional (not required) feature of theinvention. The term “connecting” includes connecting, either directly orindirectly, and “coupling,” including through intermediate elements.

The invention has been described with reference to various specific andpreferred embodiments and techniques. However, it should be understoodthat many variations and modifications may be made while remainingwithin the spirit and scope of the invention. It will be apparent to oneof ordinary skill in the art that methods, devices, device elements,materials, procedures, and techniques other than those specificallydescribed herein can be applied to the practice of the invention asbroadly disclosed herein without resort to undue experimentation. Allart-known functional equivalents of methods, devices, device elements,materials, procedures, and techniques described herein are intended tobe encompassed by this invention. Whenever a range is disclosed, allsubranges and individual values are intended to be encompassed. Thisinvention is not to be limited by the embodiments disclosed, includingany shown in the drawings or exemplified in the specification, which aregiven by way of example and not of limitation. Additionally, it shouldbe understood that the various embodiments of the building blocksdescribed herein contain optional features that can be individually ortogether applied to any other embodiment shown or contemplated here tobe mixed and matched with the features of that building block.

While the invention has been described with respect to a limited numberof embodiments, those skilled in the art, having benefit of thisdisclosure, will appreciate that other embodiments can be devised whichdo not depart from the spirit and scope of the invention as disclosedherein.

1-30. (canceled) 31: A method of installing one or more buildingcomponents at a construction site, the method comprising: lowering andcoupling a first wall panel to a rail coupled to a foundation of abuilding, the first wall panel having a first vertical stud supportedalong a first vertical edge of the first wall panel; lowering andcoupling a second wall panel to the rail, the second wall panel having asecond vertical stud supported along a second vertical edge of thesecond wall panel, wherein the first vertical stud and the secondvertical stud denote a pair of male and female connectors; and couplingthe first vertical stud of the first wall panel with the second verticalstud of the second wall panel thereby coupling the first wall panel withthe second wall panel. 32: The method of claim 31, wherein the firstwall panel includes a first bottom horizontal surface with a firstbottom connector configured to couple to a first top connector of therail to secure the first wall panel to the rail, thereby verticallyaffixing the first wall panel to the foundation. 33: The method of claim32, wherein the second wall panel includes a second bottom horizontalsurface with a second bottom connector configured to couple to a secondtop connector of the rail to secure the second wall panel to the rail,thereby vertically affixing the second wall panel to the foundation. 34:The method of claim 32, wherein the first bottom connector comprisesstuds and the first top connector comprises recesses configured toreceive the studs. 35: The method of claim 32, further comprisingscrew-fastening to the rail. 36: The method of claim 33, furthercomprising: lowering the first wall panel towards the rail until atleast a portion of the first bottom connector is inserted into the rail;lowering the second wall panel towards the rail until at least a portionof the second bottom connector is inserted into the rail; moving thesecond wall panel so that the second vertical edge aligns with the firstvertical edge of the first wall panel; fastening the first vertical studand the second vertical stud together; and securing the second bottomconnector to the rail, thereby vertically affixing the second wall panelto the foundation, adjacent to the first wall panel, to form an extendedwall on the foundation. 37: The method of claim 31, further comprisinghooking the first wall panel on a top track along a top horizontal edgeof the first wall panel before lowering the first wall panel onto therail. 38: The method of claim 31, further comprising securing a roofpanel over top horizontal edges of the first and second wall panelsthough a truss. 39: The method of claim 38, further comprising: sensing,by a sensing element, locations of the first and second wall panels andthe roof panel relative to each other and to the rail secured to afoundation; and securing the first and second wall panels to the roofpanel and the rail based on the sensed locations. 40: The method ofclaim 31, wherein the steps of lowering a first wall panel to a rail,lowering a second wall panel to the rail, and coupling the first wallpanel with the second wall panel are performed automatically by a robotassembly. 41: A method for installing one or more building components ata construction site, the method comprising: lowering a first wall panelhaving a bottom horizontal surface with a first bottom connector onto arail coupled to a foundation of a building, the rail having a tophorizontal surface with a top connector, wherein the first wall panelcomprises a first side connector; coupling the first bottom connector tothe top connector to secure the first prefabricated wall panel to therail, thereby vertically affixing the first wall panel to thefoundation; lowering a second wall panel towards the rail, the secondwall panel having a second bottom horizontal surface comprising a secondbottom connector, until at least a portion of the second bottomconnector is inserted into the rail, wherein the second wall panelcomprising a second side connector matched to the first side connector;moving the second wall panel so that the second side connector alignswith the first side connector; fastening the first and second sideconnectors together; and securing the second bottom connector to therail, thereby vertically affixing the second wall panel to thefoundation, adjacent to the first wall panel, to form an extended wallon the foundation. 42: The method of claim 41, further comprisingsecuring a roof panel over top horizontal edges of the first and secondwall panels though a truss. 43: The method of claim 42, furthercomprising coupling the roof panel with one or more other roof panels,wherein the roof panel includes one or more connectors comprising: atleast one first vertical stud supported along a first vertical face; andat least one second vertical stud supported along a second vertical faceopposite the first vertical face, wherein the at least one firstvertical stud and the at least one second vertical stud comprise a pairof male and female connectors. 44: The method of claim 43, furthercomprising coupling the at least one first vertical stud of the roofpanel with the at least one second vertical stud of the one or moreother roof panels through a screw fastener. 45: The method of claim 42,further comprising: sensing, by a sensing element, locations of thefirst and second wall panels and the roof panel relative to each otherand to the rail secured to a foundation; and securing the first andsecond wall panels to the roof panel and the rail based on the sensedlocations. 46: The method of claim 41, wherein the steps of forming theextended wall on the foundation are performed automatically by a robotassembly. 47: A system for installing one or more building components ata construction site, the building components comprising a first wallpanel, having a first roof panel, and a second wall panel, having asecond roof panel, the system comprising: an installation mechanismconfigured to: lower the first wall panel having a bottom horizontalsurface with a first bottom connector onto a rail coupled to afoundation of a building, the rail having a top horizontal surface witha top connector, wherein the first wall panel comprises a first sideconnector; couple the first bottom connector to the top connector tosecure the first prefabricated wall panel to the rail, therebyvertically affixing the first wall panel to the foundation; lower thesecond wall panel towards the rail, the second wall panel having asecond bottom horizontal surface comprising a second bottom connector,until at least a portion of the second bottom connector is inserted intothe rail, wherein the second wall panel comprising a second sideconnector matched to the first side connector; move the second wallpanel so that the second side connector aligns with the first sideconnector; fasten the first and second side connectors together; andsecure the second bottom connector to the rail, thereby verticallyaffixing the second wall panel to the foundation, adjacent to the firstwall panel, to form an extended wall on the foundation. 48: The systemof claim 47, wherein the installation mechanism comprises a mechanicalarrangement including at least a pulley. 49: The system of claim 47,wherein the installation mechanism comprises: a robot assembly; asensing element for sensing the locations of the first and second wallpanels and the first and second roof panels relative to each other andto the rail secured to the foundation; and a processor, operativelycoupled to the robot assembly and the sensing element, the processorexecuting computer-readable instructions that when executed, using therobot assembly and the sensing element, perform the steps of forming theextended wall on the foundation. 50: The system of claim 47, wherein,the installation mechanism is further configured to: align the first andsecond roof panels relative to the first and second wall panels; andsecure the first and second roof panels to each other and to the firstand second wall panels, respectively.